Electric starting device for internal-combustion engines



June 10, 1930. v, pb 1,763,549

ELECTRIC STARTING DEVICE FOR INTERNAL COMBUSTION ENGINES Filed Jan. 5, 1928 5 Sheets-Sheet l v. G. APPLE 1,763,549

ELECTRIC STARTING DEVICE FOR INTERNAL COMBUSTION ENGINES June 10, 1930.

3 Sheets-Sheet 2 VINVENTOR. W

Filed Jan, 5, 1928' June 10, 1930. v. G. APPLE 1,763,549

ELECTRIC STARTING DEVICE FOR INTERNAL COMBUSTION ENGINES Filed Jan. 5, 1928 5 Sheets-Sheet 3 INVENTOR.

Patented June 10, 1930 PATENT OFFICE VINCENT G. APPLE, OF' DAYTON, OHIO ELECTRIC STARTING DEVICE FOR INTERNAL-COMBUSTION ENGINES Application filed January 5, 1928. Serial No. 244,735.

My invention relates to electric starting devices of the class used in connection with internal combustion engines, its widest application being to that form wherein a motor is normally disconnected from the engine but which has a means associated therewith whereby the motor is connected to the engine during the time of startingand again disconnected therefrom as soon as the engine runsunder its own power, the embodiment shown employing the well known Bendix drive as the means of connection between said starting motor and engine.

One object of my invention is to construct a motor wherein no shaft bearing is required at the commutator end, of the armature, thus insuring that no oil leaking from such hearing may impair the action of the commutator and brushes.

Another object is to so construct the motor that all shaft bearings thereof extend within the flywheel housing of the engine, so that they may be oiled from the same source as other moving parts contained within said housing.

Another object is to so construct the motor that the field element thereof is a separate and distinct unit, having at one end means whereby it may align itself with the hearing carrying means, and at the other end means to align and support a brush rigging and a brush cover.

Another object is to so construct the field element of my motor that the brush rigging may be attached directly to the winding thereof, and not to loose wires or flexible leads extending therefrom as in ordinary practice.

Still another object is to provide a construction which, having no shaft hearing at the conmiutator end, permits of the removal of the entire front portion of the casing, thereby giving ready access to the brushes when renewal is necessary, or permitting inspection of the parts while the motor is running.

. Further objects will be apparent to those skilled in the art from the following detailed description wherein reference is made to the drawings, in which- I Fig. 1 is a longitudinal vertical cross section thru my motor as on the line 1-1 of Fig. 2.

Fig. 2 is a view of the motor from the commutator end, the bruslr-cover having been removed.

Flg. 3 is a fragmentary cross section taken lengthwise of the motor thru the binding post as on the line 3-3 of Fig. 2.

Fig. 4 is a fragmentary cross section taken at 4-4 Fig. 3. on

Fig. 5 shows one of the turns of the field winding specially formed for making connection to the brushes.

Fig. 6 is a cross section taken on line 6-6 of Fig. 1. a

Fig. 7 is a top view of one of the brush holders.

Fig. 8 is a detail view of one of the metal brush holder rings.

Fig. 9 is a detail view of the fibre brush 7) holder ring.

Figs. 10, 11 and 12 show several methods of mounting my starting motor 011 an engine.

Similar numerals refer to similar parts thruout the several views.

In the embodiment selected to illustrate my invention, the core or magnetic portion of the field element is in the form of a cylindrical ringcomposed of a plurality of laminae 20, having apertures 21, 21, etc., spaced about the inner circumference (see Figs. 1 and 6). Rivets 22, 22 etc., may extend thruout the length of the core to hold the lamina; together until the winding is in place. In the embodiment shown the number of winding 93 apertures in the field core is twenty-four, leaving twenty-four intervening portlons or teeth extending inwardly toward the axis as at 23. 23. 23. A loop form distributed bar winding is used, each loop having a bar 24 forming a portion of the outer layer, and a bar 25, forming a portion of the inner layer, the span of the bars of the loops being such as to magnetically divide the ring into six poles, one north and the next south around the inner circumference, each pole comprising three flux carrying teeth 23, 23 and 23. Teeth 26, 26 etc., separate the several poles and carry no flux, and, to lessen leakage from pole to pole, these teeth are shortened as shown. By forming loops having special end connecting portions the circuits thru the field winding is divided into two equal parallel paths, the terminals of which are, at one end, the binding post 27, and, at the other end, the brush connecting screw 28. As the method of providing a multipolar distributed bar lap winding having a less number of parallel paths than poles, by using loops of special form, has been made the subject of a special application (Serial No. 202,138) a complete description of the form of the loops used is not herein contained, except that one loop, more clearly shown in Figs. 3 and 4, has the closed end formed into an eye 30, and a rivet 31 extending thru this eye and the binding post 27 joins the two together, and another loop 32 shown in detail in Fig. has the closed end bent at right angles as at 33 forming an eye 34 which is suitably tapped to receive screw 28. (See Figs. 1 and 2).

After the winding is placed on the field core with the binding post joined to a loop as described, flanged covers 35 and 36 are placed over the end portions of the winding.

A short piece of square tubing of insulating material 37 is pressed over a squared portion 38 of binding post 27 thru a squared opening in cover 35. As the end openings in covers 35 and 36 may be of the same inside diameter as the field ring a cylindrical plug of this diameter may be inserted thru the structure and fluid insulating material may be poured or pumped into the space left by the windings to extend therebetween and thereabout as at 39, and hardened or allowed to harden by heat or otherwise to form a solid mass, to thus more thoroughly insulate the windings'and hold them in their relative position.

A mold or clamp placed over the flanges of covers 35 and 35 may be drawn up so as to compact the laminae 20 to a predetermined core'length' while the insulating material within the end covers is being hardened, insuring that field units made by this process will be of uniformly accurate dimensions. When the insulating material is suflicientlv hard the clamp and the cylindrical plug may be removed and the field unit will be complete.

A field element constructed as'herein described has many advantages over one of the type now commonly used in automotive starting motors wherein a length of tubing is used as the yoke portion and poles are separately made and bolted to the inside of the tube.

given diameter of field because of the large amount of magnetic material remaining when a suificient amount has been removed for the windings, and becausethere are no joints in the magnetic circuit to increase the magnetic reluctance. The magnetic joints made when poles are bolted to a yoke-are objectionable not only because they require careful and accurate machining but further because they add considerable reluctance to the magnetic circuit, which varies in similar motors or in different parts of the same motor according to the degree of accuracy attained.

A field winding of the character shown provides the shortest possible path for the electric current for a given number of turns thereby effecting economy in copper since the average length of a turn is shorter and the ineffective portions of the circuit have been reduced to a minimum. Since no two turns of the winding are immediately adjacent a better means is afforded to convey the heat from the conductors so that the motor may be operated at maximum effort for a greater period of time.

The spaced apart relation of the turns of the Winding one with another permits of a considerable amount of insulating material being molded therebetween and thereabout thus providing a maximum of insulation between the turns, forming a rigid structure, and protecting the winding against the eltect of oil and moisture as well as from physical injury.

While I greatly prefer that a laminated field element wound as herein shown and 'described be used, in carrying out this invention, such a. field structure is not absolutely essential thereto. Field cores of other form, differently wound, may be used to good effect when combined with other valuable features of this invention.

The portion of my motor comprising the brush gear is attached directly to the end of the field unit.

' A laminated ring of three layers, the two outer layers 40 and 40 being of sheet metal cut to the contour shown in Fig. 8, and the middle layer 41 of sheet insulating material cut to the contour shown in Fig. 9, is held in place by screws 28 and 42. Openings are cut in layers 40 at 43 and 44, and a portion 45 is entirely cut away. When the several layers of the ring are assembled. the cut away portion 45 of one ring is turned diainetrically opposite this cut away portion of the other. 2

Six brush holders 46 are required, each haying tenons 47 and 48 extending therefrom. The laminated ring when assembled as described has six pairs of holes 49 and 50 thru which tenons 47 and 48 may extend and he first three will be mounted on and electrical; ly connected to the other metal ring, one set.

of threebeing electrically insulated from the other set of three. Slots 51 and 52 permit of. circumferential adjustment of the brush gear when screws 28 and 42 are loosened. Thru contact of the head of screw 28 with the one outer layer three brushes are connected to loop 32 which is one terminal of the field winding. Screw 42, being positioned at a cut away portion of the outer layer 40, does not contact therewith but draws the inner layer 40 against the end of the field unit by extending into threaded hub 53, thus connecting the other three brushes to the cover 35 and thus to the ground. Portions of the metal of the inner layer 40 of the brush ring may be depressed as at 54, 54, etc., to form a dowel which may extend into the field bore to maintain concentric relation between the brush rigging and the field element.

.Brush springs 55, 55, etc., maintain suitable contact between brushes and commutator, and a short flexible'connector as at 56, may join each brush to its brush holder to insure proper contact therebetween.

In the armature, a longitudinal cross section of which appears in Fig. 1, a laminated core 57 carries a winding, each loop .ofwhich comprises two conductor bars 58 and 59 and a commutator segment 60 integrally extending at the closed end thereof, the conductor bars being endwise entered thru the core apertures until the free ends project thru and beyond the core, and the free ends being properly bent and joined in pairs to complete the circuit. Insulating material 61 is molded thru and about the winding loops to insulate them one from another, to bind the segments together into a commutatorand to form a protectix'e cover which insures against the effect of oil, moisture or other injury, A cap 62 of sheet metal furnishes additional protcction against physical injury and provides a seat against which the head of screw 64 may bear to hold the armature in position on shaft 65.

The method of making and applying an armature winding of the character shown is fully described and claimed in my Patent No. 1,631,186, and while I prefer that this. type of armature be used, the conventional type having a separate commutator may be used if desired. and while I show an armature shaft which extends only thru the. core por- 3 tion of the armature, the shaft may extend completely thru the armature if desired, and

vide a cup shaped cap Gii'WlllCll telescopes,

cover 35. Cap 66 is necessarily slotted to clear binding post 27, and the portions of the cap adjacent the binding post, made somewhat flexible because of said slot, are provided with indentures 68 which fit over corre sponding indentures 69in cover- 35 to hold the cap in place. Since cap 66 is of thin metal no great amount of force'is required to cause illtlQlltlll'ES 68 to slide over indent-ures 69 when same is being! removed. A lining 70 of insulating .material is provided'to guard against possible contact of cap 66 and brush connectors 56. By removing cap 66 the entire set of brushes may be inspected, adjusted or renewed,- and they may be inspected while the motor is running. It is obvious that by. this construction access to the brush gear is much more complete than in common practice, where a partially closed frame supports a shaft bearing at this end ofv the motor and where limited openings only are provided thru which the brushes may be viewed.

The frame or mounting bracket of my motor carries the bearings within which they armature shaft may rotate, an an annular portion, adapted to support the field unit in concentric relation with said bearings, and,

in order to make my motor more generally applicable, considerable variation in the form of the bracket employed is necessary, a common requirement being that the. two shaft bearings be sufficiently spaced apart to supply suificient rigidity to the armature core to enable it to maintain its concentric relation with the field unit.

lVhen the engine gear is so placed as to require a considerable reach between the starting motor and the gear. a bracket such as is shown in Fig. 10 may be used. This bracket has bearings 71 and 7 2, a bored portion 7 3 to which the field member is secured,

carry surplus oil in bearing 71 backwardly toward the flywheel housing rather than toward the armature. The Bendix drive shown is of standard construction and forms no part of my invention. A

-Fig. 11 shows a more approved form of mounting bracket wherein bearings 71'and' 72 are more widely spaced, apart and the Ben- (llX drive located therebetween, the greater spread of thebearmgs lnsurmg more accuracy in concentric relation of the armature and field element. The Bendix drive may be mounted as shown or it may be turned end for end if more suitable mounting conditions may be thereby secured.

The bracket Fig. 12 dispenses with the annular flange and the turned portioni' of the other brackets shown, and has instead a flange 78 which is joined by bolts 79 to a flange 80 on the fly wheel housing 81;

While the principles of my invention may find their widest application when applied to a starting motor with the Bendix drive as shown, these principles may be equally useful-when employed with other drives whether they employ a means of disconnection from the engine or are permanently connected thereto, as in a single unit starter or a charging dynamo, the more important feature of the invention consisting in the idea of selecting a compartment of the engine as a housing, providing a gear on armoving part of the engine in said housing, providing a structure which projects the pinion bearings and shaft thru an openin in the Wall of said housing, closes the opening, and supports the electrical elements outside the housing, to the end that all'of the parts to which oil is essential are within said housing and all parts t o which oil is a detriment are outside of said housing.

Having described my invention, I claim 1. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a pinion of relatively small diameter adapted to engage said gear, a shaft secured to-said pinion for rotation therewith, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the hearing at one end but having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, a dynamo electric machine field unit mounted on said bracket in concentric relation to said shaft, and a dynamo electric machine armature securely mounted in overhung fashion on the extended end of said shaft.

2. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a housing carrying a supply of oil surrounding said gear, a pinion of relatively small diameter adapted to ngagesaid gear, a shaft secured to said pinion for rotation therewith, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, said bearings and pinion being within the oil zone of said housing, a dynamo electric machine field unit mounted on said bracket in concentric relation to said shaft, and a dynamo electric machine armature securely mounted in overhung fashion on the extended end of said shaft, the electrical units being outside the oil zone of said housing.

7 3. In a starting device for an internal combastion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a pinion of relatively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when said engine is running, means to operate said pinion into and out of engagement, a shaft adapted to carry and rotate said pinion, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, an electric motor field unitmounted on said bracket in concentric rela' tion to said shaft, and an electric motor armature securely mounted in overhung fashion on the extended end of said shaft.

4. In a starting device for an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine. a housing carrying a supply of oil surrounding said gear,'a pinion of relatively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when said engine is running, means to operate said pinion into and out of engagement, a shaft adapted to carry and rotate said pinion, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, said bearings, pinion and operating means being within the oil zone of said housing, an electric motorfield unit mounted on said bracket in concentric relation to said shaft, and an electric motor armaturesecurely mounted in overhung fashion on the extended end of said shaft, the motor units being outside the oil zone of said housing.

5. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a pinion of relatively small diameter adapted to engage said gear, a shaft secured to said pinion for rotation therewith, a bracket carrying bearings for said pinion shaft, said shaft extending ashort distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame'ot' said engine as to provide suitable registry of said pinion and gear, an annular rib on said bracket concentric with said pinion shaft bearings, a dynamo electric machine field unit having at one end means for concentric location and support on said annular rib and at the other end means to support and carry current to a brush gear, and a dynamo electric machine armature securely mounted in overhung fashion on the extended end of said shaft.

. 6. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a'rotatable member of said engine, a housing carrying a supply of oil surrounding said gear, a pinion of relatively small diameter adapted to engage said gear, ashaft secured to said pinion for rotation therewlt-h, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, said bearings and pinion being within the oil zone of said housing, an annular rib on said bracket concentric with said pinion shaft bearings, a dynamo electric machine field unit having at one end means for concentric location and support on said annular rib and at the other end means to support and carry current to a brush gear, and a dynamo electric machine armature securely mounted in.

overhung fashion on the extended end of said shaft, the electrical units being outslde the oil zone of said housing.

7. In a starting device for an internal combustion engine, a gear of relativel large diameter secured to a rotatable mem er of said engine, a pinion of relatively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when said engine is running, means to operate said pinion into and out of engagement, a shaft adapted to carry and rotate said pinion, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, an annular rib on said bracket concentric with said inion shaft bearings, an electric motor field unit having at one end means for concentric location and support on said annular rib and at the other end means to support and carry current to a brush gear, and an electric motor armature securely mounted in overhung fashion on the extended end of said shaft;

8. In a starting device for an internal combustion engine, a gear ofrelatively large diameter secured to a rotatable member of said engine, a housing carrying a supply of oil surrounding said gear, a pinion of relatively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when sald engine is running, means to operate said pinion into and out of engagement, a shaft adapted to carry and rotate said pinion, a bracket carr ing bearings for said pinion shaft, said sha t extending a short distance beyond at one end. and having no further support, said bracket being so positioned on the frame of said engine .as to provide suitable registry of said pinion and gear, said bearings, pinion and operating means being Within the oil zone of said hous ing, an annular rib on said bracket concentric with saidpinion shaft bearings, an elec-' tric motor field unit having at one end means for concentric location and support on said annular rib and at the other end means to support and carry current to a brush gear, and an electric motor armature securely mounted in overhung fashion on the extended end of said shaft, the motor units being outside the oil zone of said housing.

9. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a pinion of relatively small diameter adapted to engage said gear, a shaft secured to said pinion for rotation therewith, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearings at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, an annular rib on said bracket concentric with said pinion shaft bearings, a dynamo electric machine field unit concentrically supported at one end by said annular rib, a brush gear supported on the other end of said field unit, a dynamo electric machine armature within said field unit securely mounted in overhung fashion on the extended end of said shaft, and an enclosing end supported on said field unit which, carrying no shaft bearing, may be removed to expose the brush gear and commutator while the dynamo electric machine is in operation.

10. In a dynamo electric machine adapted for service on an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine,

further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, said pinion and gear being within the oil zone of said housing, an annular rib on said bracket concentric with said pinion shaft bearings, a dynamo electric machine field unit concentrically supported at one end by said annular rib, a brush gear supported on the other end of said field unit, a dynamo electricmachine armature within said field unit securely mounted in overhung fashion on the extended end of said shaft, and an enclosing end supported on said field unit which, carrying no shaft bearing, may be removed to expose the brush gear and commutator While the dynamo electric machine isin operation, the electrical units all being'outside the oil zone of said housing.

11. In a starting device for an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a pinion of relatively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when said engine is runnirg, means to operate said pinion into and 0113 of engagement,

a shaft adapted to carry and rotate said pinion, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond the bearing at one end and havmg no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and unit securely mounted in overhu'ng fashion on the extended end of said shaft, and an enclosing end supported on said field unit which, carrying no shaft hearing, may be removed to expose the brush gear and commutator while the motor is running, the elec trical units all being outside the oil zone of said housing.

In testimony whereof I hereunto affix my name.

VINCENT G. APPLE.

gear, an annular rib on said bracket concen trio with said pinion shaft bearings, an electric motor field unit concentrically supported at one end by said annular rib, a brush gear supported on the other end of said field unit, an electric motor armature within said field unit securely mounted in overhung fashion on the extended end of said shaft, and an .enclosing end supported on said field unit which, carrying no shaft hearing, may be removed to expose the brush niutator while the motor is running.

12. In a starting device for an internal combustion engine, a gear of relatively large diameter secured to a rotatable member of said engine, a housing carrying a supply of oil surrounding said gear, a pinion of rela-' tively small diameter adapted to engage said gear to start said engine and be disengaged therefrom when said engine is running, means to operate said pinion into and out of engagement, a shaft adapted to carry and rotate said pinion, a bracket carrying bearings for said pinion shaft, said shaft extending a short distance beyond at one end and having no further support, said bracket being so positioned on the frame of said engine as to provide suitable registry of said pinion and gear, said bearings, pinion and operating means being Within the oil zone of said housing, an annular rib on said bracket concentric with said pinion shaft bearings, an electric motor field unit concentrically supported at one end by said annular rib, a brush gear supported on the other end of said field unit, an electric motor armature within said field gear and com: 

